U.S. patent number 9,604,797 [Application Number 14/005,183] was granted by the patent office on 2017-03-28 for apparatus and process for unloading load items from a loading space.
This patent grant is currently assigned to BEUMER GMBH & CO. KG. The grantee listed for this patent is BEUMER GmbH & Co. KG. Invention is credited to Heino Heitplatz, Ludger Polling, Philipp Schafer, Thomas Wiesmann.
United States Patent |
9,604,797 |
Heitplatz , et al. |
March 28, 2017 |
Apparatus and process for unloading load items from a loading
space
Abstract
An apparatus for unloading load items, comprising a receiving
conveyor having a freely projecting receiving end and a rear
delivery end, a removal conveyor and a transfer conveyor arranged
therebetween which has a front takeover end adjoining the delivery
end of the receiving conveyor and a rear handover end adjoining a
head end of the removal conveyor, wherein the transfer conveyor is
mounted so as to be pivotable in height about a first swivelling
axis arranged at the handover end, and the receiving conveyor is
mounted so as to be pivotable in height about a second swivelling
axis arranged at the delivery end, wherein the receiving conveyor
and the transfer conveyor can be moved, by being swivelled about
the first and second swivelling axes, into at least one upper
unloading position, in which the transfer conveyor is substantially
horizontal before the first swivelling axis, the receiving conveyor
is substantially vertical below the second swivelling axis and the
receiving end of the receiving conveyor is on the floor of the
loading space, or into at least one lower unloading position, in
which the receiving conveyor and the transfer conveyor are at an
angle of no more than 10.degree., 20.degree., 30.degree. or
40.degree. to the horizontal and the receiving end of the receiving
conveyor is located on the floor of the loading space, and
unloading processes using the apparatus.
Inventors: |
Heitplatz; Heino
(Drensteinfurt, DE), Polling; Ludger (Wadersloh,
DE), Wiesmann; Thomas (Beckum, DE),
Schafer; Philipp (Salzkotten, DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
BEUMER GmbH & Co. KG |
Beckum |
N/A |
DE |
|
|
Assignee: |
BEUMER GMBH & CO. KG
(Beckum, DE)
|
Family
ID: |
47749591 |
Appl.
No.: |
14/005,183 |
Filed: |
January 18, 2013 |
PCT
Filed: |
January 18, 2013 |
PCT No.: |
PCT/DE2013/000035 |
371(c)(1),(2),(4) Date: |
September 13, 2013 |
PCT
Pub. No.: |
WO2013/117177 |
PCT
Pub. Date: |
August 15, 2013 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
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US 20140348625 A1 |
Nov 27, 2014 |
|
Foreign Application Priority Data
|
|
|
|
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Feb 9, 2012 [DE] |
|
|
10 2012 003 439 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65G
67/08 (20130101); B65G 67/24 (20130101); B65G
2814/0308 (20130101) |
Current International
Class: |
B65G
59/00 (20060101); B65G 67/08 (20060101); B65G
67/24 (20060101) |
Field of
Search: |
;414/795.4,796.9,797.6,796.3,796.4,796.5
;198/300,314,312,317,588,589 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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504128 |
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Mar 2008 |
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AT |
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000010255843 |
|
Jun 2004 |
|
DE |
|
102010015299 |
|
Oct 2011 |
|
DE |
|
2006/117003 |
|
Nov 2006 |
|
WO |
|
Primary Examiner: McCullough; Michael
Assistant Examiner: Schwenning; Lynn
Attorney, Agent or Firm: Ganz Pollard LLC
Claims
The invention claimed is:
1. An apparatus for unloading load items stacked, tipped or loosely
piled on a floor of a loading space, comprising a receiving
conveyor having a freely projecting receiving end and a rear
delivery end, a removal conveyor and a transfer conveyor arranged
therebetween, which has a front takeover end adjoining the delivery
end of the receiving conveyor and a rear handover end adjoining a
head end of the removal conveyor, wherein the transfer conveyor is
mounted so as to be pivotable in height about a horizontal first
swivelling axis arranged transversely to its conveying direction at
the handover end adjacent to the head end of the removal conveyor,
and the receiving conveyor is mounted so as to be pivotable in
height about a horizontal second swivelling axis arranged
transversely to its conveying direction at the delivery end
adjacent to the transfer end of the transfer conveyor,
characterised in that the receiving conveyor and the transfer
conveyor can be moved, by being swivelled about the first and
second swivelling axes, into at least one upper unloading position,
in which a conveying surface of the transfer conveyor is
predominantly horizontal at an angle of no more than 10.degree.,
20.degree., 30.degree., or 40.degree. to the horizontal before the
first swivelling axis, a conveying surface of the receiving
conveyor is predominantly vertical at an angle of no more than
10.degree., 20.degree., 30.degree., or 40.degree. to the vertical
below the second swivelling axis and the receiving end of the
receiving conveyor is on or directly above the floor of the loading
space, or into at least one lower unloading position, in which the
conveying surfaces of the receiving conveyor and of the transfer
conveyor are predominantly horizontal at an angle of no more than
10.degree., 20.degree., 30.degree., or 40.degree. to the horizontal
and the receiving end of the receiving conveyor is located on or
directly above the floor of the loading space, wherein the freely
projecting receiving end is a terminal end.
2. The apparatus as claimed in claim 1, characterised in that the
removal conveyor is disposed at a predetermined height above the
floor, which corresponds to half the length of the receiving
conveyor.
3. The apparatus as claimed in claim 1, characterised in that the
removal conveyor can be telescoped.
4. The apparatus as claimed in claim 1, characterised in that the
receiving conveyor can be telescoped or passively adjusted in
length.
5. The apparatus as claimed in claim 1, characterised in that the
transfer conveyor and the receiving conveyor are disposed on a
common machine frame, which can be moved in a controlled manner on
a travelling unit.
6. The apparatus as claimed in claim 1, characterised in that the
transfer conveyor is wider at the takeover end than at the handover
end and is equipped with at least one lateral conveyor member,
which is in particular rectangular, triangular or trapezoidal and
tapers towards the handover end.
7. The apparatus as claimed in claim 1, characterised in that the
receiving conveyor comprises a plurality of juxtaposed receiving
conveying members.
8. The apparatus as claimed in claim 7, wherein each respective
receiving conveying member is configured to be driven and reversed
independently of the other receiving conveying member.
9. The apparatus as claimed in claim 1, characterised in that the
transfer conveyor has a plurality of juxtaposed transfer conveying
members.
10. The apparatus as claimed in claim 9, wherein each respective
transfer conveying member is configured to be driven and reversed
independently of the other transfer conveying member.
11. The apparatus as claimed in claim 1, characterised in that side
walls are disposed adjacent to the removal conveyor and/or adjacent
to the transfer conveyor, which walls run toward the middle or
inwards of the respective conveyor.
12. The apparatus as claimed in claim 11, characterised in that a
working platform for an operator is provided outside and adjacent
to a side wall.
13. A process for unloading load items stacked, tipped or loosely
piled on the floor of a loading space using an apparatus
comprising: a receiving conveyor having a freely projecting
receiving end and a rear delivery end, a removal conveyor and a
transfer conveyor arranged therebetween, which has a front takeover
end adjoining the delivery end of the receiving conveyor and a rear
handover end adjoining a head end of the removal conveyor, wherein
the transfer conveyor is mounted so as to be pivotable in height
about a horizontal first swivelling axis arranged transversely to
its conveying direction at the handover end adjacent to the head
end of the removal conveyor, and the receiving conveyor is mounted
so as to be pivotable in height about a horizontal second
swivelling axis arranged transversely to its conveying direction at
the delivery end adjacent to the takeover end of the transfer
conveyor, characterised in that the receiving conveyor and the
transfer conveyor can be moved, by being swivelled about the first
and second swivelling axes, into at least one upper unloading
position, in which a conveying surface of the transfer conveyor is
predominantly horizontal at an angle of no more than 10.degree.,
20.degree., 30.degree., or 40.degree. to the horizontal before the
first swivelling axis, a conveying surface of the receiving
conveyor is predominantly vertical at an angle of no more than
10.degree., 20.degree., 30.degree., or 40.degree. to the vertical
below the second swivelling axis and the receiving end of the
receiving conveyor is on or directly above the floor of the loading
space, or into at least one lower unloading position, in which the
conveying surfaces of the receiving conveyor and of the transfer
conveyor are predominantly horizontal at an angle of no more than
10.degree., 20.degree., 30.degree., or 40.degree. to the horizontal
and the receiving end of the receiving conveyor is located on or
directly above the floor of the loading space, wherein the freely
projecting receiving end is a terminal end; wherein in a first
step, the apparatus is moved to an upper unloading position, and a
load item located above a predetermined unloading height or above
the transfer conveyor is transferred directly to the transfer
conveyor, and in a second step, the apparatus is moved to a lower
unloading position, and a load item located below the predetermined
unloading height or on the floor of the loading space is
transferred to the receiving conveyor.
14. The process as claimed in claim 13, characterised in that in
the first step, the apparatus is moved successively or alternately
into a first upper unloading position and into a second upper
unloading position, wherein the takeover end in the first upper
unloading position is at a greater height above the floor than in
the second upper unloading position.
15. The process as claimed in claim 13, characterised in that
transferring at least those load items located above the transfer
conveyor onto the transfer conveyor is supported manually by
operator , especially by means of an auxiliary tool.
16. The process as claimed in claim 13, characterised in that
before or during the first step, the apparatus is advanced as far
as possible into the loading space, until the receiving conveyor,
which is in particular in a vertical position, comes to rest
against load items.
17. The process as claimed in claim 13, characterised in that the
first and second steps are repeated alternately, until the loading
space has been completely unloaded.
18. The process as claimed in claim 3, characterised in that any
load item lying on the floor of the loading space is picked up by
moving the apparatus while it is in a lower unloading position in a
direction opposite to the conveying direction.
Description
The invention relates to an apparatus for unloading load items
stacked, tipped or loosely piled on a floor of a loading space,
such as parcels, cardboard boxes, crates and similar packed items,
comprising a receiving conveyor having a freely projecting
receiving end and a rear delivery end, a removal conveyor and a
transfer conveyor arranged therebetween which has a front takeover
end adjoining the delivery end of the receiving conveyor and a rear
handover end adjoining a head end of the removal conveyor, wherein
the transfer conveyor is mounted so as to be pivotable in height
about a first swivelling axis arranged transversely to its
conveying direction at the handover end and adjacent to the head
end of the removal conveyor, and the receiving conveyor is mounted
so as to be pivotable in height about a second swivelling axis
arranged transversely to its conveying direction at the delivery
end and adjacent to the takeover end of the transfer conveyor.
The invention further relates to a process for unloading load items
stacked, tipped or loosely piled on a floor of a loading space,
using such an apparatus.
An apparatus and a process of the type mentioned are used in
particular for unloading load items in the manner of bulk material
from loading spaces of vehicles, also in the form of swap bodies or
swap body tank containers, the latter being replaceable freight
carriers, which can be transported by a carrier vehicle (lorry) and
separated from it.
The object of the invention is thus not the individualised
unloading of items, where each item is picked and handled
individually, but rather unloading preferably in the manner of bulk
material, where a high throughput of, for example, at least 3,000
items/hour is desired.
DE 10 2010 015 299 A1 discloses a system for handling load items
for preferably automatically loading and unloading a loading space
in which the load items are stacked one on top of the other; in
that system, a number of conveyor belts arranged one behind the
other in series are provided, some of which are mounted so as to be
pivotable and adjustable in height and enable the transfer of load
items directly from a position where the respective load item is
stored at a particular height to a receiving conveyor, from where
the load items are delivered to a removal conveyor via a transfer
conveyor. The receiving conveyor is always aligned substantially
horizontally at different heights in order to receive load
items.
If they are load items of a substantially uniform size which are
stacked in an orderly manner, it is possible to work
advangtageously with such a system. Problems do, however, occur
whenever individual load items have distinctly uneven dimensions
and/or are stacked irregularly, because then it frequently happens
that individual load items fall down next to the receiving conveyor
onto the floor of the loading space or onto other load items. Quite
apart from the fact that the load items are in danger of being
damaged as a result of falling down, there is a risk that load
items might be trapped when the receiving conveyor is powered down.
In addition, there is the difficulty of using the receiving
conveyor to pick up load items in a suitable way when they have
fallen down in an uncontrolled manner and are lying around on the
floor in disarray.
The problem on which the invention problem is based is to propose
an improved apparatus and an improved process for unloading load
items stacked on a floor of a loading space, in which the
above-mentioned problems are at least partially solved.
In an apparatus of the generic kind, this problem is solved by the
following measures: the receiving conveyor and the transfer
conveyor can be moved, by being swivelled about the first and/or
second swivelling axes, into at least one upper unloading position,
in which one conveying surface of the transfer conveyor is
predominantly horizontal, i.e. at an angle of no more than
10.degree., 20.degree., 30.degree. or 40.degree. to the horizontal,
before the first swivelling axis; one conveying surface of the
receiving conveyor is predominantly vertical, i.e. at an angle of
no more than 10.degree., 20.degree., 30.degree. or 40.degree. to
the vertical, below the second swivelling axis; and the receiving
end of the receiving conveyor is on or directly above the floor of
the loading space; or the transfer conveyor can be moved into at
least one lower unloading position, in which the conveying surfaces
of the receiving conveyor and the transfer conveyor are
predominantly horizontal, i.e. at an angle of no more than
10.degree., 20.degree., 30.degree. or 40.degree. to the horizontal,
before the second swivelling axis, and the receiving end of the
receiving conveyor is located on or directly above the floor of the
loading space.
In a preferred or first upper unloading position, the conveying
surface of the receiving conveyor is inclined by no more than
10.degree. to the vertical, and is in particular in a vertical
position beneath the takeover end of the transfer conveyor, and the
conveying surface of the transfer conveyor is inclined by less than
20.degree. to 40.degree., preferably 25.degree. to 35.degree. to
the horizontal, dropping in the conveying direction. In a preferred
second upper or middle unloading position, the receiving conveyor
adopts a position as in the preferred upper unloading position,
while the conveying surface of the transfer conveyor is disposed in
a range between 10.degree. to the horizontal, rising in the
conveying direction, and preferably between 5.degree. and
15.degree., dropping in the conveying direction.
In a preferred lower unloading position, the transfer and receiving
conveyors are inclined at the same angles, rising in the conveying
direction, especially at 10.degree. to 30.degree., and abut each
other continuously. This forms a continuous first conveying
surface, which is substantially flat.
In an upper or the preferred upper unloading position, there is the
advantage that the receiving conveyor forms a delimitation of the
takeover end of the transfer conveyor towards the floor, so that
any load items that might possible fall down in an uncontrolled way
can under no circumstances enter an area beneath the transfer
conveyor, i.e. between the floor of the loading space and the
transfer conveyor, whereas in the lower unloading position any load
item lying on the floor in an orderly or disorderly way can be
picked up relatively unproblematically.
It is convenient for there to be, in addition to the conveyor
drives for the conveyors, drives for the swivelling movement at
least of the transfer conveyor, and optionally also of the
receiving conveyor, for example an hydraulic drive, a servomotor or
a stepping motor with transmissions for the transfer and optionally
also the receiving conveyor. The receiving conveyor may be
suspended from the transfer conveyor so as to be capable of
swivelling freely, so that in the lower unloading position it
adopts a steeper position or its vertical position solely as a
result of the fact that the transfer conveyor is swivelled up
towards an upper unloading position. Conversely, in this case, the
receiving conveyor adopts an increasingly flatter position,
proceeding from a vertical position, for instance by swivelling
down the takeover conveyor, since the receiving end is resting on
the floor or on a roller a small distance from the floor.
The removal conveyor can be disposed at a predetermined height
above the floor, especially in a horizontal orientation, wherein
the predetermined height may be about one length to half a length
of the receiving conveyor. The transfer conveyor and the removal
conveyor may be arranged horizontally in an upper unloading
position or sloping downwards in the conveying direction and abut
each other continuously. This forms a continuous second conveying
surface. All together, since the receiving, transfer and removal
conveyors each abut each other continuously, the first and second
conveying surfaces form a continuous conveying surface.
The free receiving end of the receiving conveyor, which faces away
from the removal conveyor, may have a width which is 1.5 to 3 times
a width of the removal conveyor, and in particular a width of 2 to
3 m, in order to be able to unload transport receptacles such as
containers. The receiving conveyor preferably has a constant width
over its length, whereas the transfer conveyor has a width which
reduces gradually between its receiving and handover ends, with no
sharp transitions, down to the width of the removal conveyor.
It is preferably contemplated that the receiving conveyor can be
telescoped or passively adjusted in length. In the case of an
embodiment which can be telescoped, the receiving conveyor can be
actively and infinitely changed in length in both directions. In
the case of an embodiment in which the length can be adjusted
passively, there is an initial length in an unloaded state, where
the length of the receiving conveyor can be shortened under the
effect of a force acting on the receiving end in its conveying
direction against a restoring force exerted by a restoring spring
and returns to the initial length when the force ceases to act. The
variable length of the receiving conveyor allows a certain
flexibility with regard to the height above the floor at which the
removal conveyor and the transfer conveyor may be disposed when
aligned horizontally. The shortest possible length of the receiving
conveyor may, for example, be no more than 90%, 80%, 70%, 60% or
50% of an initial length in the unshortened state. The receiving
conveyor may be equipped with a safety cut-off, which switches off
the conveyor drive of the receiving conveyor if it falls short of a
predetermined length, such as when the shortest possible length is
reached, and/or if a predetermined force acting on the receiving
end in the conveying direction is exceeded. The safety cut-off may
also be adapted such that it switches off a downward swivelling
movement of the transfer conveyor as soon as less than the
predetermined length of the receiving conveyor is reached and/or a
predetermined force acting on the receiving end in the conveying
direction force is exceeded.
In the lower unloading position, a receiving conveyor which is
adjustable in length against the restoring force of a spring can be
pressed gently against the load item lying on the floor, without
damaging it. If the pressing force exceeds a predetermined value,
the receiving conveyor yields, shortening its length. In this way,
compensation for the amount of travel is achieved for the
travelling unit.
The invention conveniently contemplates that the removal conveyor
can be telescoped, as a result of which, if the removal conveyor is
extended, its head end and the first swivelling axis are displaced
opposite to the conveying direction, and the transfer and receiving
conveyors can, for example, be moved into a loading space.
The removal conveyor can be telescoped in or against its conveying
direction by means of a travelling unit which can be moved on the
ground, such as the floor of the loading space. Although it is in
principle possible for the removal conveyor, the transfer conveyor
and the receiving conveyor to be units that can be moved
separately, it is convenient for the removal conveyor and the
transfer conveyor to be disposed on a common travelling unit which
can be moved as a whole. The travelling unit can preferably be
moved forwards, backwards or diagonally forwards/backwards without
changing its orientation, i.e. without rotating about its own
vertical axis.
The travelling unit may possess drivable and steerable rollers with
which a desired travelling movement can be executed. It is
convenient for three steerable rollers to be disposed at the
corners of an isosceles or non-isosceles triangle, the steering
positions or steering directions of which are identical and which
are synchronised by means of a motor-driven belt or chain
drive.
The travelling unit preferably has lateral distance sensors, such
as in the form of ultrasonic or optical sensors, in order to detect
a lateral distance on each side from a wall or the like. Per side,
it is possible to provide two or more distance sensors arranged
spaced apart horizontally from one another. In addition, two laser
pointers may be provided pointing forwards in the longitudinal
direction as an entry and steering aid.
At a front end of the travelling unit, near the floor, it is
possible to provide a light barrier disposed transversely, with
which articles such as load items can be detected which cannot be
seen by the operator and which might damage the travelling unit as
it passes. At the front end and preferably also on both sides of
the travelling unit there is a deflector brush or strip which
extends as far as or almost as far as the floor, in order to
prevent the unit from travelling over any load items that might
have been overlooked.
The travelling unit may be connected to the removal conveyor by
means of two parallel coupling rods in order to allow a certain
tolerance between their respective positions.
It may be contemplated that the transfer conveyor is wider at the
takeover end than at the handover end and is equipped with at least
one lateral conveyor member which is in particular rectangular,
triangular or trapezoidal and tapers towards the handover end.
Alternatively, the transfer conveyor may possess a triangular or
trapezoidal roller path, the rollers of which are divided along a
longitudinal central line and are adjusted to converge in a slight
V-shape in order to create a conveying component towards the
middle. It is convenient for the receiving conveyor to be just as
wide as the transfer conveyor at its takeover end, and the transfer
conveyor is preferably just as wide at its handover end as the
removal conveyor at its head end.
The receiving conveyor may have a plurality of receiving conveying
members arranged parallel, side by side, which can be driven and
reversed independently of one another, also at different speeds,
and can be telescoped or adjusted passively in length. The transfer
conveyor may have a plurality of transfer conveying members
arranged parallel, side by side, which can be driven and reversed
independently of one another, also at different speeds. The
receiving and/or transfer conveyor may be configured so as to be
shock-absorbing in order to lessen the shocks of any load items
that might fall down and to handle them gently, such as by means of
shock-absorbing conveyor belts, for example consisting of or coated
with elastic material, or by means of sprung-mounted rollers in the
case of a roller conveyor.
It may be contemplated that fixed and/or movable side walls are
disposed on one or both sides adjacent to the removal conveyor
and/or on one or both sides adjacent to the transfer conveyor
and/or on one or both sides adjacent to the receiving conveyor,
wherein the side walls may be vertical or may slope diagonally
outwards, in order to prevent load items from falling off the
transfer conveyor or the removal conveyor.
A working platform for an operator may be provided to the left
and/or right, seen in the conveying direction, adjacent to the
transfer conveyor and/or the removal conveyor, and in particular
outside and adjacent to a side wall. The operator can control the
movements and conveying speeds of the travelling unit, removal
conveyor, transfer conveyor and receiving conveyor manually or may
operate a control system which is already installed, and with which
the drives for the conveyors and the swivelling movements about the
first and second swivelling axes and the travelling unit can be
controlled, so that the apparatus can be moved into a desired
unloading position or receiving position and then moved as needed.
In particular, it is possible to program or store a number of
different upper and/or lower unloading positions in the control
system, so that a suitable unloading position can be selected as
required, in which the receiving conveyor and the transfer conveyor
each adopt a predetermined inclination and, if necessary, are moved
to a desired position by moving the apparatus, such as by being
driven a greater or lesser distance into or out of the loading
space.
In the case of an operator working right-handedly, it is convenient
to arrange the working platform to the left of the removal
conveyor, seen in the direction of the receiving conveyor, since a
manipulation device or auxiliary tool held by the operator in his
right hand, such as a rod, lance, grip or hook, is then closer to
the middle of the conveyors than if it is arranged to the right of
the removal conveyor.
The invention further relates to a process for unloading load items
stacked on a floor of a loading space using an apparatus in
accordance with the invention, wherein in a first step, the
apparatus is moved to an upper unloading position, and a load item
located above a predetermined unloading height or above the
transfer conveyor, is transferred to the transfer conveyor, and in
a second step, the apparatus is moved to a lower unloading
position, and a load item located below the predetermined unloading
height or on the floor of the loading space is transferred to the
receiving conveyor. Load items located above a predetermined
unloading height are preferably placed on the transfer conveyor
with manual assistance from an operator, who moves the load items
onto the transfer conveyor with an auxiliary tool, such as a rod
with a gripping tool attached. Load items from the floor are
preferably picked up and placed on the receiving conveyor solely by
means of the drive of the receiving conveyor, in combination with a
gentle forward movement of the travelling unit towards the load
items to be picked up, optionally assisted by the operator.
During the first step, various upper unloading positions are
possible, preferably a first upper unloading position, in which the
takeover end is at a first height, such as at the greatest possible
height above the floor with the receiving end still touching the
floor, or slightly higher, such as 5 mm to 2 cm above it, while the
receiving conveyor adopts a vertical position and its initial
length is not shortened, and a second upper or middle unloading
position, in which the takeover end is at a second height, which is
lower than the first height, such as at the lowest possible height
above the floor, in which the receiving conveyor is shortened as
far as possible and adopts a vertical position. Between these
extreme positions, any intermediate positions can be adopted.
Before or during the first step, the apparatus is preferably
advanced as far as possible into the loading space opposite the
conveying direction or towards the load items to be picked up,
until the receiving conveyor, which is preferably in a vertical
position, comes to rest against load items so that, as far as
possible, any load items falling or down pulled down from above
fall directly onto the transfer conveyor and not onto the floor in
front of the receiving conveyor. Before or during the second step,
the apparatus can be moved into a number of successive lower
unloading positions, in particular into the preferred lower
unloading position, wherein the receiving conveyor, proceeding from
its vertical position, is moved into the upper unloading position,
in one or more steps or infinitely, towards a sloping or
substantially horizontal position, while the receiving end is
located on or directly above the floor. During or before the second
step, the apparatus can be moved further forward into the loading
space or towards the load items to be unloaded, such as while,
before or after the apparatus has been moved into a different upper
unloading position.
The first and second steps may be repeated alternately if required,
until the loading space has been completely unloaded. Any load
items lying on the floor of the loading space can be picked up by
moving the apparatus towards the load items concerned, or contrary
to the conveying direction, with the apparatus in the lower
unloading position.
One advantage of the invention is that the operator has to perform
virtually no lifting work during the unloading, because the load
items to be unloaded and picked up by the apparatus merely have to
be pulled down from their stacked position or pulled from a lying
position at least partially onto the receiving conveyor. A further
aspect is that the operator is well-protected against any load
items that might fall down.
The invention will now be explained by describing a worked
embodiment of the apparatus and process, reference being made to a
drawing, in which
FIG. 1 shows a schematic perspective view of the apparatus of the
invention, wherein a receiving position is illustrated,
FIG. 2 shows a perspective view of the apparatus in a transport
position,
FIG. 3 shows a view corresponding to FIG. 2 when driving into a
loading space or container loaded with load items,
FIG. 4 shows a side view, in a longitudinal section in the front
area, of the apparatus in the position illustrated in FIG. 3,
FIG. 5 shows a perspective view of the apparatus in a first upper
unloading position,
FIG. 6 shows a side view, in a longitudinal section in the front
area, of the apparatus in the position illustrated in FIG. 5,
FIG. 7 shows a perspective view of the apparatus in a second upper
or middle unloading position,
FIG. 8 shows a side view, in a longitudinal section in the front
area, of the apparatus in the position shown in FIG. 7,
FIG. 9 shows a perspective view of the apparatus in a lower
unloading position,
FIG. 10 shows a side view, in a longitudinal section in the front
area, of the apparatus in a position in accordance with FIG. 9,
FIG. 11 shows an enlarged schematic side view of the receiving end
of the receiving conveyor in the lower unloading position,
FIG. 12 shows a schematic plan view of the apparatus with the head
end of the removal conveyor,
FIG. 13 shows a schematic plan view of the travelling unit, and
FIG. 14 shows a view of the apparatus from the front.
FIGS. 2 to 4 show the apparatus in a transport position, in which
the apparatus has been moved into a compact position in which the
receiving conveyor 6 hangs down freely on the second swivelling
axis 30, while FIG. 1 shows the apparatus in a lower unloading
position.
The apparatus comprises a removal conveyor 2, a transfer conveyor 4
and a receiving conveyor 6, which are disposed so as to abut each
other directly. Any spaces or gaps between adjacent conveyors are
at least smaller than a smallest dimension (thickness, width,
height, diameter etc.) of the load items to be unloaded, e.g.
smaller than 5 cm, 3 cm, 2 cm or 1 cm. The conveyors may be
disposed on a common machine frame such that they are firmly
connected together, or they may be arranged independently of one
another as individual conveyors, whose position can be changed in
accordance with the invention. In the context of the present
description, the receiving and transfer conveyors are disposed as a
unit on a common frame, on a travelling unit 8 which allows the
conveyors 2, 4 and 6 to be moved along and transversely to a
longitudinal direction 10 which is identical to a conveying
direction 12 of the conveyors.
FIG. 12 shows a schematic plan view of a head end 2a of the removal
conveyor 2 of the apparatus, and FIG. 13 shows a plan view of the
travelling unit 8 and its connection to the head end 2a of the
removal conveyor 2. The removal conveyor 2 and travelling unit 8
are connected together via two coupling rods 3, which permit a
certain relative mobility in the sense of a tolerance to compensate
for uneven ground between the removal conveyor 2 and the travelling
unit 8. On its underside, the travelling unit 8 has three steering
rollers 3b each steerable about a vertical steering axis 3a, at
least one of which is driven by a motor so that the travelling unit
8 can be driven forwards, backwards or diagonally. The steering
axes 3a are preferably disposed at corners of an isosceles or
equilateral triangle, the steering rollers 3b being coupled
together in an identical steering position via a chain drive 3c,
which is motor-driven by a steering drive 3d, and are in this way
synchronised in their steering position. This ensures that during
translational movements, the travelling unit 8 is not rotated about
a vertical axis, but always maintains its orientation that can be
seen in FIG. 13 and its alignment in the longitudinal direction 10.
Two lateral distance sensors 8a help the positioning when the
apparatus is being driven into the loading space between lateral
walls 9.
The removal conveyor 2 is configured as a telescope conveyor,
wherein only a head end 2a and an adjoining initial portion of the
removal conveyor 2 are shown, but not a delivery end opposite the
head end 2a. In the case of a delivery end fixed in a stationary
position, the entire part of the apparatus illustrated in FIG. 1
can be moved back and forth on the car 8 in the longitudinal
direction 10 without impairing the removal of load items. In a
preferred application for emptying a container, trailer or swap
body laden with loose load items, for example laden with packages
and parcels, the head end 2a of the removal conveyor 2 can in this
way be advanced opposite to the conveying direction 12, entraining
the transfer conveyor 4 and the receiving conveyor 6 in the
process, by moving the travelling unit 8 until the receiving
conveyor 6 is standing directly in front of or is already in
contact with stacked or piled load items.
The receiving conveyor may have a plurality of receiving conveying
members, arranged parallel, side by side, which can be driven and
reversed independently of one another, also at different speeds,
and can be telescoped or adjusted passively in length (indicated by
the double-ended arrows in FIG. 1). The transfer conveyor may have
a plurality of transfer conveying members arranged parallel, side
by side, which can be driven and reversed independently of one
another, also at different speeds (indicated by the double-ended
arrows in FIG. 1).
In the embodiment illustrated, the transfer conveyor 4 is multiply
subdivided and consists of four transfer conveying members disposed
side by side in the form of belt conveyors with conveyor belts 4a,
a further belt conveyor downstream with a conveyor belt 4b and a
roller path 4c arranged to the side, which forms a substantially
triangular or trapezoidal conveying surface. The roller path 4c has
rollers arranged diagonally to the longitudinal direction 10 in
order to create a conveying component directed to a vertical
longitudinal central plane of the removal conveyor 2. Lateral
deflector plates 4d, e (FIGS. 1, 14) form a transition between
moving conveying members of the transfer conveyor and side walls
36, which are described further down. The transfer conveyor 4 thus
has a conveying surface which extends between a front takeover end
16, a rear handover end 18 and two lateral edges. It goes without
saying that the transfer conveyor 4 is not limited to the
combination of conveyor belts and roller paths illustrated, but
could be realised completely or partly with conveyor belts, link
belts, roller paths or other conveying constructions. The lateral
deflector plates 4d, e may be configured transversely to the
conveying direction 12 and sloping upwards in order to achieve a
desired effect of guiding load items towards the removal conveyor
2. A rectangular part 4b, 4a, 4a of the conveying surface runs in
an extension of the removal conveyor 2 (FIG. 12), and a trapezoidal
part 4c, 4a, 4a is located beside it to the right, seen in the
conveying direction.
The removal conveyor 2 preferably extends horizontally, a conveying
surface of the removal conveyor at the head end 2a of the removal
conveyor 2 being arranged at a predetermined height H above a floor
22 on which the travelling unit 8 rests and travels. The height H
may be between 30 cm and 1 m for example. In principle, it is
desirable that the height above the floor should not be too great
so that, in the lower unloading position, the receiving and
takeover conveyors 4, 6 are not at too great an upward incline to
bridge the difference in height between the floor and the removal
conveyor. An upward incline between the receiving conveyor and the
transfer conveyor of between 10.degree. and 30.degree. to the
horizontal is advantageous.
In the transport position illustrated in FIGS. 2 to 4 and in the
unloading positions illustrated in FIGS. 5 to 8, the receiving
conveyor 6 is arranged vertically in each case and extends
vertically downwards from the takeover end 16 of the takeover
conveyor 4 to just above the floor 22, for example 1 mm to 10 mm
above it (unloading position), or ends at a greater distance, for
example 5 to 15 cm, above the floor (transport position). In the
embodiment illustrated, the receiving conveyor 6 also consists of a
row of individual receiving conveying members or conveyor belts 6a
in the form of belt conveyors with conveyor belts 6g (FIG. 11)
arranged side by side, wherein each conveyor belt 6a is passively
adjustable in length. With appropriate pressure against a front
receiving end 6b of the receiving conveyor 6 or the individual
conveyor belts 6a, the conveyor belt 6a' shortens against the
pressure of a restoring spring and lengthens back to its initial
length when the force is removed.
FIGS. 2 to 4 and FIGS. 9, 10 show an initial length L of the
receiving conveying members 6a and of the receiving conveyor 6 in
contrast to the shortened or minimal lengths of the receiving
conveying members 6a according to FIGS. 7, 8. The characteristics
of passive telescoping can be adjusted such that the receiving
conveyor 6 can already be shortened in response to a slight force
acting in the conveying direction 12, or such that the receiving
conveyor 6 can only be shortened as of a certain minimum force, the
strength of which can be set as a threshold.
The transfer conveyor 4 is mounted so as to be pivotable in height
about a first swivelling axis 26, which is disposed horizontally
and transversely to the conveying direction 12 in a fixed position
adjacent to the head end 2a of the removal conveyor 2, and is thus
adjustable in height in its front portion, especially with its
takeover end 16. The receiving conveyor 6 is pivotable in height
about a second swivelling axis 30, which is disposed horizontally
and transversely to the conveying direction 12 adjacent to the
takeover end 16 of the transfer conveyor 4, and is thus adjustable
in height in its receiving end 6b, relative to the takeover end, so
that there are a wide range of adjustment possibilities for the
transfer and receiving conveyors 4, 6. In the context of the
invention, it is contemplated that the receiving end 6b of the
receiving conveyor 6 is always located on the floor 22 or directly
above the floor 22.
When the transfer conveyor 4 is configured as a belt or roller
conveyor, the first swivelling axis 26 preferably runs through a
drive or return roller of the transfer conveyor 4 located at the
handover end 18, or through an adjacent return roller of the
removal conveyor 2. In a similar manner, when the receiving
conveyor is configured as a belt or roller conveyor, the second
swivelling axis 30 preferably runs through a drive or return roller
of the receiving conveyor 6 located at the delivery end 6c, or
through a drive or return roller located at the takeover end 16 of
the transfer conveyor 4.
The conveying surface of the transfer conveyor 4 in the area of the
handover end 18 is preferably a certain degree above an adjacent
end of the conveying surface of the removal conveyor 2 in order to
prevent small load items from becoming trapped in the transition
region between the transfer and removal conveyors. This can be
achieved by, for example, having a drive or return roller disposed
at the handover end 18 of the transfer conveyor 4 at the same
height as, or higher than, a drive or return roller located at the
head end 2a of the removal conveyor 2, wherein the first swivelling
axis 26 runs through the drive or return roller at the handover end
18. A corresponding arrangement is preferably provided between the
receiving and transfer conveyors, it being convenient that a drive
or return roller located in the region of the delivery end 6c
through which the second swivelling axis 30 runs is disposed at the
same height as, or higher than, a drive or return roller located at
the takeover end 16 of the transfer conveyor 4.
Disposed next to the removal conveyor 2 are side walls 34 (and 35,
indicated by dashed lines in FIGS. 1, 12), which extend over at
least part of the length of the removal conveyor 2 in the region of
its head end 2a, especially beginning at the head end 2a. Further
side walls 36a, b are provided laterally, next to the transfer
conveyor 4. The side walls 34, 35, 36a, b are disposed closely
adjacent to the respective conveyors and prevent individual load
items from falling down beside the conveyors. The side wall 36b,
which runs towards the middle or inwards facilitates the transport
of load items on the removal conveyor 2 when they are located
off-centre on the transfer conveyor 4 or the receiving conveyor 6,
in that the load items are given a conveying component directed
towards the longitudinal central plane of the removal conveyor.
Extendable side walls 37, 38 extend next to the receiving conveyor
6. FIGS. 1 and 10 illustrate one embodiment. The side walls 38 are
pivotably hinged at the upper corner 38a to the side walls 36a, b
disposed next to the transfer conveyor 4 and may be connected in an
articulated manner to the front end or receiving end 6b by means of
a linear guide 38b which can be telescoped, so that they are
extended automatically when the receiving conveyor 6 is moved from
an upper to the lower unloading position and vice versa.
To the side of the head end 2a of the removal conveyor 2 and/or
next to a region of the transfer conveyor 4 adjacent to it there is
a horizontal working platform 40, which can be firmly mounted at a
predetermined height, such as at a height of 0.5 H, above the floor
22 or it may be adjustable in height, wherein an operator 42
standing on the working platform 40 can adjust the height manually.
Alternatively, the height adjustment can be performed automatically
in connection with the selection or extension of a particular
unloading or receiving position by means of a control system
configured accordingly. In order to protect the operator 42, the
side wall 36b can be of a predetermined height in the region of the
working platform 40 and enclose a protected working area 44 in a
curved or angled path. A door 45 enables the operator to enter the
receiving or transfer conveyor when it is standing still, for
example to remove any conveying items that are not capable of being
conveyed.
The side walls 36a disposed opposite the working platform 40 next
to the transfer conveyor (to the left when seen in the conveying
direction 12 in the example illustrated) are either disposed
parallel to the longitudinal direction 10 or at a small angle of
about 5.degree. to 20.degree., preferably no more than 10.degree.,
their spacing increasing from a longitudinal central plane of the
removal conveyor 2 counter to the conveying direction. The side
walls 36b disposed on the side of the working platform 40 (disposed
to the right when seen in the conveying direction in the example
illustrated) run at an angle of approx. 30.degree. to 60.degree. to
the longitudinal direction 10 in a region adjacent to the working
platform 40, and virtually parallel to the longitudinal direction
in a region located between the working platform and the receiving
conveyor next to the transfer conveyor 4.
Brushes or profile members of elastic material or gap-bridging
means acting in a similar way may be attached to the side walls
36a, b or 38 and/or laterally of the receiving conveyor 6 to
compensate for dimensional tolerances, such as uneven surfaces of
side walls of a loading space to be unloaded, so that no load items
fall down to the side or slip between the side walls and the wall
of the loading space or in the event of a crooked position of the
load carrier. As FIG. 4 shows, at the front and optionally also at
the sides, deflector members in the form of brushes 46 or profile
members may be disposed on the car 8, so that any load items that
may happen to be lying on the floor are not run over.
For use, the apparatus is first arranged in the first upper
unloading position illustrated in FIGS. 4 to 6, in the second upper
unloading position illustrated in FIGS. 7, 8 and then in the lower
unloading position illustrated in FIGS. 1, 9 and 10, in which load
items can be picked up from the floor 22 and transported to the
removal conveyor 2 by means of the receiving and transfer conveyors
6, 4. Because the transfer conveyor 4 can be swivelled about the
first swivelling axis 26 and the receiving conveyor 6 can be
swivelled about the second swivelling axis 30, differently inclined
lower unloading positions are possible, apart from the "straight"
and preferred position illustrated in FIGS. 1, 9 and 10, in which
the receiving conveyor 6 is at the same angle of inclination of
about 10.degree. to 30.degree. to the horizontal as the transfer
conveyor 4, so that the two conveyors are substantially disposed in
a common plane. As an alternative to this position, the receiving
conveyor 6 may be disposed more steeply than the transfer conveyor
4, such as at 20.degree. to 40.degree., which results in an
intermediate position between the unloading position according to
FIGS. 7, 8 and the one according to FIG. 1, or less steeply than
the latter, such as at 0.degree. to 20.degree., so that the second
swivelling axis 30 or a transition region which comprises the
delivery end 6c of the receiving conveyor 6 and the takeover end 16
of the transfer conveyor 4 are disposed at a lower height above the
floor 22 than in the position illustrated in FIG. 1. A maximum
position is reached when the second swivelling axis 30 is located
directly above the floor 22 and the receiving conveyor 6 is
arranged horizontally to the floor. A lower unloading position like
this can be advantageous in order to pick up load items lying on
the floor.
In order to unload load items stacked on a floor of a loading
space, such as parcels and packages from a container or a swap
body, the apparatus is first driven in the transport position
(FIGS. 2 to 4) with the aid of the car 8 close up to a loading
opening of the loading space on its floor 22. Whether the apparatus
is moved into an upper unloading position corresponding to the
first or second upper unloading positions or into a lower unloading
position depends essentially on whether the load items in the
container are stacked higher than a certain height or not, and on
the nature and sensitivity of the load items, i.e. on whether they
can fall onto the receiving conveyor from the stacked height
without the risk of damage when the conveyor is in a receiving
position, or whether there is a risk of damage and it is preferable
only to allow the load items to drop onto the transfer conveyor
which is in the first or second upper unloading position at a
substantially greater height than the receiving conveyor in the
lower unloading position. In the case of load items with a certain
sensitivity, such as postal parcels where no damage is to be
expected if they drop from a height of up to 1 m, it is possible to
work in a lower unloading position, provided that the load items
are not stacked substantially higher than 1 m. In the case of
greater stacking heights, it is necessary to work first in an upper
unloading position, such as in the first or second upper unloading
position, and then in the lower unloading position.
As a rule, in a first step, work is first performed in the first
upper unloading position, in which the operator 42 uses an
auxiliary tool 50 to move load items which do not drop onto the
transfer conveyor 4 of their own accord from their stacked position
onto the transfer conveyor 4. The auxiliary tool 50 may be a tube
or rod of aluminium, wood or plastic, e.g. carbon, which has a
gripping tool 52 attached to it at the end facing away from the
operator, which in the simplest case may be a hook or a plate
arranged vertically to the tube or rod. Alternatively or in
addition, a suction or needle gripper in a single or multiple
configuration may be provided as the gripping tool. In addition,
depending on the specific situation, it is possible for the
operator to select one of many different auxiliary tools and thus a
suitable gripping tool. Depending on the situation, the operator
can either grasp behind a load item or grasp it from the front with
a gripper and pull it out of the stacked position or knock it over,
whereupon the load item drops onto the transfer conveyor 4
substantially in a free fall. From there, the load item is
transported by the transfer conveyor onto the removal conveyor 2
and from there delivered to a destination point arranged in
advance. When the receiving conveyor 6 is standing vertically, it
in effect merely ensures in this unloading position that no load
items slip beneath the receiving conveyor.
Following unloading activity in the first upper unloading position,
it is possible to continue unloading in a second upper or middle
unloading position, which is illustrated in FIGS. 7 and 8. Compared
to the first upper unloading position according to FIGS. 4 to 6,
the transfer conveyor is swivelled down by a certain angle about
the first swivelling axis 16, the receiving conveyor 6 remaining
aligned vertically and standing on the floor 22, its length now
being shortened to the maximum extent. In the second upper
unloading position, the receiving conveyor 4 can have a slight
inclination, such as no more than 10.degree., 20.degree. or
30.degree. to the horizontal, or may be aligned horizontally.
In a second step, the apparatus is moved to a suitable lower
unloading position, i.e. the transfer conveyor 4 is swivelled
downwards about the first swivelling axis 26, and the receiving
conveyor 6 is simultaneously or previously swivelled in the
opposite swivelling direction, either passively solely by the
transfer conveyor or actively by means of a corresponding
swivelling drive, until a desired angular position of the two
conveyors is reached, wherein the receiving end 6b of the receiving
conveyor 6 is disposed on or directly above the floor 22. A number
of different lower receiving positions are also possible. The
receiving end of the receiving conveyor is preferably located
during the entire adjustment process on or directly above the
floor, so that no load items can slip beneath the receiving
conveyor. During or before the second step, the apparatus can first
be moved in the conveying direction away from the load items to be
picked up, in order to enable or support the adjustment movement of
the receiving conveyor, and then moved forwards towards the load
items to be unloaded, so that the receiving end of the receiving
conveyor remains in or comes into contact with the load items to be
picked up. It is advantageous if, during the adjustment process
and/or while the apparatus is being driven towards the load items
to be unloaded, the receiving conveyor already executes a conveying
movement in the conveying direction 12 so that, as far as possible,
a load item that comes into contact with the receiving end
immediately begins to be picked up, such as by being lifted on one
side, so that as the apparatus continues to advance towards the
load items to be unloaded, in many cases load items lying on the
floor are already picked up automatically.
In the event of malfunction situations, in which load items are
located in front of the receiving conveyor or to the side between
the receiving conveyor or transfer conveyor and a wall, the
operator will first attempt to pull the load items onto the
receiving conveyor with the aid of the auxiliary tool. During this
process, the conveyors remain in operation.
Apart from that, the operator can briefly drive individually
selected or all the conveyor belts or roller paths in a direction
opposite to the conveying direction 12, i.e. reverse them, in order
to release a jam.
In the event that load items become jammed in the area of the head
end of the removal conveyor, the operator can reach over the side
wall either by hand or with an auxiliary instrument, in order to
eliminate the malfunction, or he can step on the transfer or
removal conveyor. For this purpose, the door 45 may possess a
safety device which either switches off the receiving and transfer
conveyors when the door is opened or enables the door to be opened
only when the conveyors are switched off.
FIG. 11 shows an enlarged detailed lateral view of the receiving
end 6b of the receiving conveyor 6, where a supporting roller 6d
can be seen, which is mounted with a horizontal pivot axis 6e on
the receiving conveyor 6 and which supports the receiving conveyor
6 on the floor 22 so that it can be easily displaced. It can be
seen that as of a certain angle of inclination of the receiving
conveyor 6, when it is made steeper, the supporting roller 6d lifts
off the floor 22, as a result of which the receiving end 6b of the
receiving conveyor 6 then first rests on the floor 22 on supporting
members 6f. If the receiving conveyor or conveyors 6 is/are placed
at a steeper angle by swivelling, the supporting members 6f also
lose contact with the floor, and the conveyor belt 6g of the
receiving conveyor comes into contact with the floor before the
receiving conveyor is lifted off the floor completely.
List of reference numerals
2 removal conveyor 2a head end 3 coupling rod 3a steering axis 3b
steering roller 3c chain drive 3d steering drive 4 transfer
conveyor 4a conveyor belt 4b further conveyor belt 4c roller path
4d, e deflector plate 6 receiving conveyor 6a, 6a' conveyor belt
(receiving conveying member) 6b receiving end 6c delivery end 6d
supporting roller 6e pivot axis 6f supporting member 6g conveyor
belt 8 car (travelling unit) 8a distance sensor 9 lateral loading
space wall 10 longitudinal direction 12 conveying direction 16
takeover end 18 handover end 22 floor 26 first swivelling axis 30
second swivelling axis 34, 35, 36a, b, 37, 38 side wall 38a corner
(hinge point) 38b linear guide 40 working platform 42 operator 44
working area 45 door 46 brush (deflector member) 50 auxiliary tool
52 gripping tool H height (of 2) L length (of 6)
* * * * *